Compositions and processes for optimizing oxygen reduction and oxygen evolution reactions

ABSTRACT

Compositions and processes for optimizing oxygen reduction and oxygen evolution reactions are provided. Oxygen reduction and oxygen evolution catalysts include oxide compositions having a general formula a formula A 2-x MO y , where x is electrochemically tuned to find optimal A content that delivers the best catalytic performance in a chemical system. The process provides the ability to find the optimal catalytic performance by tuning A and hence, the binding strength of O.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.16/429,648, filed Jun. 3, 2019, which is incorporated herein byreference in its entirety.

TECHNICAL FIELD

Compositions and process for optimizing oxygen reduction and oxygenevolution reactions are provided. More specifically, oxygen reductionand oxygen evolution catalyst materials are provided that can beoptimized by adjusting an oxygen vacancy formation energy or oxygenbinding energy and stabilized via adjusting an electrolyte composition.

BACKGROUND

Fuel cells are receiving increasing attention as a viableenergy-alternative. In general, fuel cells convert electrochemicalenergy into electrical energy in an environmentally clean and efficientmanner. Fuel cells are contemplated as potential energy sources foreverything from small electronics to cars and homes. In order to meetdifferent energy requirements, there are a number of different types offuel cells in existence today, each with varying chemistries,requirements, and uses.

Electrolyzers which split H₂O into H₂, a potential fuel, and O₂, ananodic byproduct of water electrolysis, typically use rare materialslike Pt as cathodes and IrO₂ or RuO₂ as anodes. In the reverse process,a fuel cell converts H₂ fuel and an O₂ reagent into H₂O using similarlyrare Pt and rare-earth oxide catalysts, extracting the energy from theelectrons shuttled between the oxidation of H₂ and the reduction of O₂at the fuel cell anode and cathode, respectively. Although preciousmetal catalysts like Pt, IrO₂, and RuO₂ typically do accelerate thereactions involved, these devices are still inhibited by slow reactionkinetics of both the oxygen evolution reaction (OER) and oxygenreduction reaction (ORR) at the electrolyzer anode and fuel cellcathode, respectively.

Typical metal-air batteries comprise anodes that are formed using metalssuch as zinc (Zn), aluminum (Al) and lithium (Li) and typical fuel cellscomprise H₂ gas oxidized in an anode reaction to produce protons(hydrogen ions), often on a catalyst such as Pt. During the discharge ofsuch batteries and fuel cells, oxidation of the metal or H₂ occurs atthe anode, which releases electrons which are transported via anexternal circuit to a cathode. At the cathode, an oxygen reductionreaction occurs, converting oxygen from air and water from anelectrolyte into hydroxide ions in zinc-air and aluminum-air batteries,or converting oxygen from air to an oxide of anode-metal (e.g. Li₂O₂) inlithium-air batteries or converting oxygen from air to water by reactionwith protons. In zinc-air batteries in particular, hydroxide ions thenmigrate through the electrolyte to reach the anode where they form ametal salt (e.g. zincate), which decays into a metal oxide (e.g. zincoxide). As such, the metallic anode gradually becomes depleted over timein a primary metal-air battery, thus requiring a continuous supply ofmetal for long term operation. However, the depletion of the anode canbe mitigated by introducing oxygen evolution reactions at the cathodewhile the battery or the fuel cell is not being discharged. This resultin oxygen reduction reactions occurring at the anode, which in turncauses metal to be regenerated at the anode. However, the oxygenreduction reaction (ORR) and the oxygen evolution reaction (OER) havelarge overpotentials and sluggish reaction kinetics.

Catalysts for oxygen reduction reaction or oxygen evolution reactionplay key roles in enabling wide spread use of new technologies, such asfuel cells. Limiting factors in the wide scale commercialization of bothORR and OER include the efficiency and costs associated with theprecious metals that are used to produce effective catalysts. Hence,there is a need for more efficient and less expensive ORR and OERcatalysts.

SUMMARY

In one form of the present disclosure, an oxygen reduction reactionand/or oxygen evolution reaction catalyst includes a composition havinga general formula A_(2-x)MO_(y), where A is Li, y is 2 to 3, and Mcomprises a precious metal. The composition has an oxygen vacancyformation energy or oxygen binding energy of about −1 to about 1 eV/atomobtained by electrochemically tuning x in a range of 0 to 2.

In another form of the present disclosure, an oxygen reduction reactionand/or oxygen evolution reaction catalyst includes a composition havinga general formula A_(2-x)MO_(y), where A is Li, y is 3, and M comprisesa precious metal selected from at least one of Rh, Ir, Ru, Pd, Au, Ag,Os and mixtures thereof. The composition has an oxygen vacancy formationenergy or oxygen binding energy of about −1 to about 1 eV/atom obtainedby electrochemically tuning x in a range of 0 to 2.

In still another form of the present disclosure, a process foroptimizing oxygen reduction or oxygen evolution catalytic activityincludes providing an oxygen reduction and/or oxygen evolution reactioncatalyst having a general formula of A_(2-x)MO_(y), where A is Li,wherein x is 0 to 2, wherein y is 2 to 3, and M comprises a preciousmetal selected from at least one of Rh, Ir, Ru, Pd, Au, Ag, Os andmixtures thereof. The process includes electrochemically tuning aninitial value of x to improve catalytic activity of oxygen reduction oroxygen evolution reactions. In some variations, the process includeselectrochemically tuning an amount of A by applying a current to the ORRand/or OER catalyst to provide an oxygen binding strength for absorptionor desorption of oxygen.

BRIEF DESCRIPTION OF FIGURES

So that the manner in which the above recited features of the presentinvention can be understood in detail, a more particular description ofthe invention, briefly summarized above, may be had by reference toembodiments, some of which are illustrated in the appended drawings. Itis to be noted, however, that the appended drawings illustrate onlytypical embodiments of this invention and are therefore not to beconsidered limiting of its scope, for the invention may admit to otherequally effective embodiments.

FIG. 1 describes oxygen vacancy formation energies of Li_(2-x)MO₃materials as a function of delithiation (x ranging between 0 and 2).

FIG. 2 shows a Pourbaix diagram used for determining the stability ofthe compositionally tuned layered material near oxygen evolutionreaction potentials.

DETAILED DESCRIPTION

The following description is not to be taken in a limiting sense, but ismade merely for the purpose of describing the general principles ofexemplary embodiments. The scope of the invention should be determinedwith reference to the claims.

Cost effective catalysts material are provided that possess improvedactivity and stability, and which may include less expensive materials.The oxide compositions include compositions having a general formulaA_(2-x)MO_(y). In this aspect, x is a “handle” to find optimal A contentthat would deliver the best catalytic performance in a chemical system.

A process is provided for optimizing oxygen reduction or oxygenevolution catalytic activity. The process provides the ability to findthe optimal catalytic performance or highest OER or ORR reaction rate orthe lowest overpotential at a given current density for the givencatalytic material, by tuning A and hence, the binding strength of O.The ability to electrochemically control the content of A, provides a“dynamic” catalyst, where one can apply and alternate between two biasesto shift back and forth between two A contents in A_(2-x)MO_(y), in anelectrochemical setup, to dynamically tune the catalyst “on-the-fly” foroptimal adsorption and desorption stages for catalytic reaction.

Oxide Compositions

Li-ion or similar rechargeable battery electrodes can be utilized andmobile ion content can be tuned to control the electronic structure ofthe material that governs O binding and ultimately the ORR or OERcatalytic activity. Optimal catalytic activity is achieved atdelithiation levels near, but before the evolution of O₂ (i.e. dischargestates of electrodes normally avoided in Li-ion battery operations). Ifthese layered materials are delithiated too deeply below a certain Licontent, then the oxygen in the material destabilizes and tends to formO—O dimers and evolve as O₂ gas or react with other materials in theenvironment. This Li content threshold is a function of the structure ofthe oxide, chemical identity of the redox active or inactive metals, andother factors.

Oxide compositions include compounds having a general formulaA_(2-x)MO_(y). In this aspect, these layered materials include a mobileion A, where A is an alkali metal such as lithium (Li) or sodium (Na).Li and Na are useful for electrochemically tuning a binding strength ofoxygen.

Further to the general formula, M is a metal ion that may have multiplenominal oxidation states. In this aspect, M may include metals such ascobalt (Co), manganese (Mn), iron (Fe), nickel (Ni), titanium (Ti),vanadium (V), germanium (Ge), zirconium (Zr), molybdenum (Mo), hafnium(Hf), osmium (Os), ruthenium (Ru), rhodium (Rh), lead (Pb), tin (Sn),iridium (Jr), platinum (Pt), gold (Au), silver (Ag), and mixturesthereof. In another aspect, M includes metal ions such Pt, Rh, Jr, Ru,Pd, Au, Ag, Os and mixtures thereof.

In one aspect, M is a single element, and in another aspect, M is amixture of elements. A mixture of M may include metals such as Pt, Rh,Jr, Ru, Pd, Au, Ag, Os and one or more elements that include Fe, Mn, Cu,and Ni. M may include any ratio of these elements. Some examples ofelement combinations include Pt/Fe, Rh/Ni and Pd/Mn and similarcombinations.

The oxide composition has an oxygen vacancy formation energy or oxygenbinding energy of about −1 to about 1 eV/atom. The oxygen bindingstrength, and therefore the ORR or OER catalytic performance of theoxide composition, can be controlled by altering the electronicstructure of Li-ions in Li-metal oxide or similar Na-ion, Na-metaloxide.

For example, in a Li-rich Li₂MnO₃ electrode, Mn has a nominal oxidationstate of 4+. As Li is being removed, the nominal oxidation state of Mnstarts increasing. However, in actuality, electronic states of Mn(d-electrons) and O (p-electrons) are overlapping and with Li removal,electrons normally associated with O are being removed as well, inducinga valence state of −2+m for O. As this continues, and the electronicstructure of O anion become more and more unfavorable for binding (i.e.nominal valence approaching −1, after a certain point, O-dimer formationin the material can be favored, and O₂ gas may subsequently evolve. TheLi_(2-x)MnO₃ material system can be scanned within 0<x<2 to find anoptimal catalytically active composition, presence of which is expectedfrom the demonstrated controllability of oxygen vacancy formation energyby tuning of x in FIG. 1.

FIG. 1 describes oxygen vacancy formation energies of Li_(2-x)MnO₃materials as a function of delithiation (x). The figure demonstrates theability to control 0 binding of strength of different metal oxidecompositions via Li content. In this aspect, the oxide composition is alayered crystal structure capable of insertion and desorption of lithiumor sodium ions. Outside the range of oxygen vacancy formation or bindingenergy where optimal material composition delivering the best catalyticactivity (measured in terms of the current density) is, the currentdensity would effectively be an order of magnitude lower. In thisaspect, a current density for an optimal material composition deliveringa significant catalytic activity is about 1 mA/cm² or greater.

The oxide compositions may be provided as part of an electrode. In oneaspect, surface areas of oxide compositions are enhanced by providingthe oxide compositions in a nanoparticle structure or in a nanosheetstructure.

Optimizing Oxygen Reduction or Oxygen Evolution Catalytic Activity

A process for optimizing oxygen reduction or oxygen evolution catalyticactivity includes providing a metal oxide having a general formulaA_(2-x)MO_(y) and electrochemically tuning an initial value of x toimprove catalytic activity of oxygen reduction or oxygen evolutionreactions. The initial value of x before tuning may be theas-synthesized composition of A_(2-x)MO_(y).

The metal oxide of the general formula is a layered material thatincludes a mobile ion where A is an alkali metal such as lithium (Li) orsodium (Na). Li and Na are useful for electrochemically tuning a bindingstrength of oxygen. Further to the general formula, M is a metal ionthat may have multiple nominal oxidation states. In this aspect, M mayinclude metals such as cobalt (Co), manganese (Mn), iron (Fe), nickel(Ni), titanium (Ti), vanadium (V), germanium (Ge), zirconium (Zr),molybdenum (Mo), hafnium (Hf), osmium (Os), ruthenium (Ru), rhodium(Rh), lead (Pb), tin (Sn), iridium (Ir), platinum (Pt), gold (Au),silver (Ag), and mixtures thereof. In another aspect, M includes metalions such Pt, Rh, Ir, Ru, Pd, Au, Ag, Os and mixtures thereof. In oneaspect, M is a single element, and in another aspect, M is a mixture ofelements. A mixture of M may include metals such as Pt, Rh, Ir, Ru, Pd,Au, Ag, Os and one or more elements that include Fe, Mn, Cu, and Ni.

The oxide composition is a layered crystal structure capable ofinsertion and desorption of lithium or sodium ions. In this aspect, theprocess includes electrochemically tuning an initial value of x byapplying a bias or current to the metal oxide composition to provide anoxygen binding strength for adsorption or desorption of oxygen. Thevalue of x is adjusted to provide the oxide composition with an oxygenvacancy formation energy or oxygen binding energy of about −1 to about 1eV/atom. The tuning may depend upon the desired catalytic activity.

Maintaining Electrochemical Stability of an Oxide Composition

A process for maintaining electrochemical stability of an oxidecomposition in an oxygen reduction or oxygen evolution reaction includesproviding a metal oxide having a general formula A_(2-x)MO_(y) and anelectrolyte composition and preparing the metal oxide composition tohave a region of stability in the Pourbaix diagram encompassing the OERor ORR working electrochemical potential and pH values. The electrolytecomposition includes a salt of M and/or a salt of A.

The metal oxide of the general formula is a layered material thatincludes a mobile ion where A is an alkali metal such as lithium (Li) orsodium (Na). Li and Na are useful for electrochemically tuning a bindingstrength of oxygen. Further to the general formula, M is a metal ionthat may have multiple nominal oxidation states. In this aspect, M mayinclude metals such as cobalt (Co), manganese (Mn), iron (Fe), nickel(Ni), titanium (Ti), vanadium (V), germanium (Ge), zirconium (Zr),molybdenum (Mo), hafnium (Hf), osmium (Os), ruthenium (Ru), rhodium(Rh), lead (Pb), tin (Sn), iridium (Ir), platinum (Pt), gold (Au),silver (Ag), and mixtures thereof. In another aspect, M includes metalions such Pt, Rh, Ir, Ru, Pd, Au, Ag, Os and mixtures thereof. In oneaspect, M is a single element, and in another aspect, M is a mixture ofelements. A mixture of M may include metals such as Pt, Rh, Ir, Ru, Pd,Au, Ag, Os and one or more elements that include Fe, Mn, Cu, and Ni. Inthis aspect, the oxide composition is a layered crystal structurecapable of insertion and desorption of lithium or sodium ions.

As shown in FIG. 2, a Pourbaix diagram can be used to determine thestability of the compositionally tuned layered material near the oxygenevolution reaction potentials. Electrode potential can be adjusted inconjunction with O-binding strength for ensuring stability in the OER orORR reaction regions. The potential of the electrode changes with Licontent and shifts upward as more Li is removed. A and M concentrationsin the electrolytes can be utilized to adjust the location of electrodepotentials.

Conditions or parameters of aqueous solution systems within a system aremonitored and maintained relative to the metal oxide stability area (orco-precipitation or metal oxide stability area when other metals areprocessed) with regard to electrochemical (oxidizing) potential (Eh)range and pH range at the prescribed system molarity, temperature andpressure in order to provide an Eh-pH combination to achieve stablesolution equilibrium, as defined by the metal oxide stability area asdelineated in, for example a Pourbaix Diagram. The process includesselecting an appropriate pH range for use with the particular metal saltand solvent employed by reference to a Pourbaix diagram. The lines inthe Pourbaix Diagram show the equilibrium conditions, that is, where theactivities are equal, for the species (or reaction products) on eachside of that line. On either side of the line, one form of the specieswill instead be said to be predominant. The pH, and/or the suitable pHagent, is selected such that the formation of the metal oxide species ispredominant over the formation of the metal hydroxide species.

FIG. 2 illustrates that by adjusting A and/or M salt concentration inelectrolyte, one can shift or modify the shape of the stability region(as illustrated by arrows shown) for A_(2-x)MO₃ (catalyst), and hencemake it relatively more stable under OER or ORR conditions.

In another aspect, electrochemical stability is enhanced by adding asalt of M and or a salt of A in the electrolyte. Layered crystalmaterials may be exfoliated and dispersed in an electrolyte to exposemore surface area for catalytic activity.

Pourbaix diagram encompassing the metal oxide of interest can beobtained in advance from the literature or from theoreticalcalculations, and/or stability can be step by step controlled byincremental additions of salts of M or Li into the electrolyte.Electrolyte would normally have a large affinity for the dissolved ionsof M and Li if it does not contain these ions upfront, hence candestabilize the metal oxide and result in its dissolution/degradation.The gradual addition of the corresponding M and/or Li salts intoelectrolyte can be used as a mechanism to lower the mentioned affinityof electrolyte for these ions, and support stabilization of thecatalyst.

For example, if the metal oxide is not stable under the pH andelectrochemical potential pertaining to its catalytic reaction (ORR orOER), addition of a salt of M to the electrolyte may stabilize it byincreasing the chemical potential of M in the electrolyte (or decreasingthe electrolytes affinity for M). Similarly, if the metal oxide is notstable under the pH and electrochemical potential pertaining to itscatalytic reaction (ORR or OER), addition of a salt of Li to theelectrolyte may stabilize it.

Example: Manufacture of Batteries Using Metal Oxide CatalystCompositions

Batteries, such as for example lithium air batteries, may utilize themetal oxide compositions as catalysts. An example of manufacturing thelithium air battery is as follows. First, metal oxide catalyst, aconducting agent, and a binder are mixed, and then are added to anappropriate solvent to prepare a positive electrode slurry. The positiveelectrode slurry is coated and dried on a surface of a currentcollector, optionally followed by press-molding in order to improve theelectrode density, thereby preparing a positive electrode.

Next, a negative electrode is mounted in one side of a case, and thepositive electrode with a separator is mounted in another side oppositeto the negative electrode, wherein the separator is disposed on the sideof the positive electrode facing toward the negative electrode. Anelectrolyte is injected between the positive electrode and the negativeelectrode, a porous current electrode is disposed on the positiveelectrode, and a pressing member that allows air to reach the positiveelectrode is pushed to fix a cell, thereby completing the manufacture ofthe lithium air battery. A lithium ion conductive solid electrolytemembrane may be further disposed on one surface of the negativeelectrode.

The case may be divided into upper and lower parts, which contact thenegative and positive electrodes, respectively. An insulating resin maybe disposed between the upper and lower parts to electrically insulatethe positive and negative electrodes from each other.

The lithium air battery may be either a lithium primary battery or alithium secondary battery. The lithium air battery may have any ofvarious shapes, and in some embodiments, may have a shape like a coin, abutton, a sheet, a stack, a cylinder, a plane, or a horn. The lithiumair battery may be used as a large-scale battery for electric vehicles.

During discharge of the battery, oxygen flows into the composite cathodefrom the outside and undergoes an oxygen reduction reaction (ORR) withlithium ions derived from the anode to produce a lithium oxide. On theother hand, during charge of the battery, oxidation of the lithium oxideoccurs in an oxygen evolution reaction (OER), and lithium ions migrateto the anode and are electrodeposited as lithium metal.

While the invention herein disclosed has been described by means ofspecific embodiments, examples and applications thereof, numerousmodifications and variations could be made thereto by those skilled inthe art without departing from the scope of the invention set forth inthe claims.

What is claimed is:
 1. An oxygen reduction reaction (ORR) and/or oxygenevolution reaction (OER) catalyst comprising a formula A_(2-x)MO_(y);wherein A is Li, wherein y is 2 to 3, wherein M comprises a preciousmetal, wherein the ORR and/or OER catalyst has an oxygen vacancyformation energy or oxygen binding energy of about −1 to about 1 eV/atomobtained by electrochemically tuning x in a range of 0 to
 2. 2. The ORRand/or OER catalyst of claim 1 wherein M comprises at least one of Rh,Jr, Ru, Pd, Au, Ag, Os and mixtures thereof.
 3. The ORR and/or OERcatalyst of claim 1 wherein M is at least one of Rh, Pd, and mixturesthereof.
 4. The ORR and/or OER catalyst of claim 1 wherein M is at leastone Ru, Jr, and mixtures thereof.
 5. The ORR and/or OER catalyst ofclaim 1 wherein M is selected from the group consisting of Pt/Fe, Rh/Ni,and Pd/Mn.
 6. The ORR and/or OER catalyst of claim 1 wherein the ORRand/or OER catalyst is a layered crystal structure capable of insertionand desorption of lithium ions.
 7. The ORR and/or OER catalyst of claim1 wherein the ORR and/or OER catalyst is provided in a nanoparticlestructure.
 8. The ORR and/or OER catalyst of claim 1 wherein the ORRand/or OER catalyst is provided in a nanosheet structure.
 9. An oxygenreduction reaction (ORR) and/or oxygen evolution reaction (OER) catalystcomprising a formula A_(2-x)MO_(y); wherein A is Li, wherein y is 3,wherein M comprises is a precious metal selected from at least one ofRh, Jr, Ru, Pd, Au, Ag, Os and mixtures thereof, wherein the ORR and/orOER catalyst has an oxygen vacancy formation energy or oxygen bindingenergy of about −1 to about 1 eV/atom obtained by electrochemicallytuning x in a range of 0 to 2, and the ORR and/or OER catalyst isprovided in an at least one of a nanoparticle structure and a nanosheetstructure.
 10. The ORR and/or OER catalyst of claim 9 wherein M is atleast one of Rh, Pd, and mixtures thereof.
 11. The ORR and/or OERcatalyst of claim 9 wherein M is at least one Ru, Jr, and mixturesthereof.
 12. The ORR and/or OER catalyst of claim 9 wherein M isselected from the group consisting of Pt/Fe, Rh/Ni, and Pd/Mn.
 13. TheORR and/or OER catalyst of claim 9 wherein the ORR and/or OER catalystis a layered crystal structure capable of insertion and desorption oflithium ions.
 14. A process for optimizing oxygen reduction or oxygenevolution catalytic activity, the process comprising: providing anoxygen reduction (ORR) and/or oxygen evolution reaction (OER) catalystof a formula A_(2-x)MO_(y); wherein A is Li, wherein x is 0 to 2,wherein y is 2 to 3, wherein M comprises a precious metal selected fromat least one of Rh, Jr, Ru, Pd, Au, Ag, Os and mixtures thereof; andelectrochemically tuning an initial value of x to improve catalyticactivity of oxygen reduction or oxygen evolution reactions.
 15. Theprocess of claim 14 wherein M is at least one of Rh, Pd, and mixturesthereof.
 16. The process of claim 14 wherein M is at least one of Ru,Jr, and mixtures thereof.
 17. The process of claim 14 wherein M isselected from the group consisting of Rh/Ni and Pd/Mn.
 18. The processof claim 14 wherein the electrochemically tuning of an initial value ofx includes applying a bias to the ORR and/or OER catalyst.
 19. Theprocess of claim 14 wherein the process includes electrochemicallytuning an amount of A by applying a current to the ORR and/or OERcatalyst to provide an oxygen binding strength for absorption ordesorption of oxygen.
 20. The process of claim 14 wherein the ORR and/orOER catalyst is a layered crystal structure capable of insertion anddesorption of lithium ions.